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CORN HEADSO P E R A T O R ' S M A N U A L

CH2112

CH2208

November 2011 Edition

i

Introduction

READ THIS MANUAL carefully to learn how to oper-ate and service your machine correctly. Failure to do so could result in personal injury or equipment dam-age.

This manual and safety signs on your machine may also be available in other languages. (See your Fron-tier dealer to order.)

THIS MANUAL SHOULD BE CONSIDERED a per-manent part of your machine and should remain with the machine when you sell it.

MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench.

RIGHT-HAND AND LEFT-HAND sides are deter-mined by facing in the direction the implement will travel when going forward.

Introduction

WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Specification section. Accurately record all the numbers to help in tracing the machine should it be stolen.Your dealer also needs these numbers when you or-der parts. File the identification numbers in a secure place off the machine.

WARRANTY is provided as part of Frontier’s support program for customers who operate and maintain their equipment as described in this manual. The war-ranty is explained on the warranty certificate which you should have received from your dealer.

This warranty provides you the assurance that Fron-tier will back its products where defects appear within the warranty period. In some circumstances, Fron-tier also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused, or modi-fied to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpow-ering machines will result in such action.

P/N 5XB00251-B

01-ii

(THIS PAGE LEFT INTENTIONALLY BLANK)

Index-1

Item Page Item Page

Index

12-Row Auger Adjustment Only ...................... 45-1150, 60 and 70 Series Combines with Variable Speed Feeder House ..................... 35-39400, 9410, 9500, 9510, 9600 and 9610 Combines With Variable-Belt-Drive Feeder House .............................................. 35-3

A

Active Header Control Display .......................... 40-2Adjust Corn Head Properly ............................... 35-1Adjusting and Leveling Gatherer Points ........... 45-1Adjusting Auger .............................................. 45-10Adjusting Auger Drive Chain ........................... 45-12Adjusting Deck Plates ....................................... 45-4Adjusting Gatherer Chain Flights ...................... 45-3Adjusting Gatherer Chain Tension .................... 45-3Adjusting Row Unit Drive Chain ....................... 45-7Adjusting Row Unit Drive Sprockets With (ONLY) Fixed Speed Drive (Combines) ....... 45-8Adjusting Row Unit Drive Sprockets With (ONLY) Fixed Speed Drive (Corn Huskers) .......................................... 45-10Adjusting Row Unit Drive Sprockets With (ONLY) Fixed Speed Drive (Forage Harvesters) ..................................... 45-9Adjusting Slip Clutches ..................................... 45-7Adjusting Trash Knives ..................................... 45-2Adjust Row Spacing ......................................... 45-5Alternative and Synthetic Lubricants ................ 50-2Annually or Every 200 Hours of Operation ....... 55-3Armrest Functions ............................................ 40-1Attaching and Detaching Corn Head to Forage Harvester or Corn Husker ............. 20-10Attaching Corn Head to Feeder House ............ 20-1Attaching Corn Head to Pre 60 Series Combine ...................................................... 25-1Auger ............................................................... 35-12Auger Floor Clean Out Door ............................. 55-2

B

Beginning of Season Service ........................... 70-2

C

Calibration Error Codes .................................... 40-1Center Gatherer Shields ..................................... 30-1Chopping Gear Cases (Optional) ................... 35-10Combines With Fixed Speed Feeder House .... 35-4Corn Head Drive Speeds .................................. 35-2Corn Head Engage/Disengage Drive ............... 35-2Corn Head Grease ........................................... 50-1Corn Head Safety Features .............................. 05-1Coupling the Chain ......................................... 45-11

D

Deck Plate Control Display ............................... 40-3Description of Automatic Header Height Control System ............................................ 40-4Detaching Corn Head from Feeder House ....... 20-6Drive and Operate Carefully ............................. 35-1

E

Ear Savers ........................................................ 35-8End of Season Service ..................................... 70-1Every 1000 Hours of Operation ........................ 55-6

F

Feeder House Latching Pins (Cleanout) .......... 20-9Feeder House Manual Unlatching .................. 20-10

G

Gatherers .......................................................... 35-5Grease .............................................................. 50-1

H

Harvesting Corn With Weakened or Broken Stalks ............................................... 35-4Harvesting Popcorn .......................................... 35-4Header Warning Light Bulb Replacement ........ 65-8Height Sensing and Active Header Float Pressure Sensitivity (Automatic Functions) .................................................... 40-5Hydraulic Adjustable Deck Plates ..................... 35-9Hydraulic Cylinder Safety Stop ................55-1, 65-1

K

Keep Machines Secure .................................... 75-2

L

Latching Cable Shear Screw Location ........... 20-10Level Land Feeder House Lower End Cable — Adjusting ....................................... 20-9Lowering ACTIVE HEADER CONTROL Ground Sensors (Optional) .......................... 35-7Lubricant Storage ............................................. 50-2Lubrication Symbols ......................................... 55-2

M

Machines Equipped with Button Lock Multi-couplers .............................................. 20-3Machines Equipped with Slide Lock Multi-couplers .............................................. 20-3Manual Raise/Lower Speed(Manual Functions) ........................................... 40-6

Index-2

Item Page Item Page

Index

O

Outer Gatherer Extensions ............................. 35-12Outer Gatherer Shields....................................... 30-2

P

Proof of Ownership ........................................... 75-2

R

Raising and Removing Center Gatherer Shields and Points ....................................... 35-5Raising and Tilting End Fenders and Points ..... 35-7Remove and Install Oil Pan .............................. 65-6Remove and Install Stalk Rods ........................ 65-1Removing, Flipping, and Installing Chopping Knife Blades .............................. 35-11Replacing Gatherer Chain ................................ 65-5Reversing Gatherer Chains and Sprockets for Additional Wear ....................................... 65-4Row Units ......................................................... 35-8

S

Safety Decal Locations ..................................... 15-1Serial Number ................................................... 75-2Single Point Latching — Adjusting .................... 20-7Specifications ................................................... 75-1Stalk Rolls ......................................................... 35-9Starting in the Field ........................................... 35-1Stubble Light Bulb Replacement ...................... 65-7Stubble Lights ................................................. 35-12

T

Transporting Corn Head on a Trailer ................ 30-1Troubleshooting ................................................ 60-1Troubleshooting - Active Header Control (AHC) ........................................................... 60-4Torque Charts ............................................75-3, 75-4

W

Wear Strips ....................................................... 65-7When to Calibrate ............................................. 40-1

01-1

ContentsItem Page

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is

reserved to make changes at any time without notice.

Item PageCorn Head Safety Features Corn Head Safety Features ...........................05-1

Safety Recognize Safety Information ........................10-1 Understand Signal Words ..............................10-1 Wear Protective Clothing ...............................10-1 Follow Safety Instructions ..............................10-2 Prepare for Emergencies ...............................10-2 Store Attachments Safely ..............................10-2 Ballasting for Safe Ground Contact ...............10-3 Parking and Leaving the Combine .................10-3 Avoid Contact With Moving Parts ..................10-3 Use Safety Lights and Devices ......................10-4 Road Transport Disconnect Switch (Black) ...10-4 Transport Combine With Header Safely ........10-5 Stay Clear of Header .....................................10-5 Avoid Tanglement ..........................................10-5 Stay Clear of Rotating Drivelines ...................10-6 Practice Safe Maintenance ............................10-6 Service Machines Safely ...............................10-7 Guards and Shields .......................................10-7 Support Machine Properly .............................10-8 Avoid High Pressure Fluids............................10-8 Remove Paint Before Welding or Heating .....10-9 Avoid Heating Near Pressurized Fluid Lines .10-9 Dispose of Waste Properly ..........................10-10 Replace Safety Signs ..................................10-10

Safety Decal Locations Safety Decal Locations ..................................15-1

Attaching and Detaching Attaching Corn Head to Feeder House ..........20-1 Machines Equipped with Slide Lock Multi-couplers ................................................20-3 Machines Equipped with Button Lock Multi-couplers ................................................20-3 Detaching Corn Head from Feeder House ....20-6 Single Point Latching — Adjusting .................20-7 Level Land Feeder House Lower End Cable — Adjusting .........................................20-9 Feeder House Latching Pins (Cleanout) ........20-9 Feeder House Manual Unlatching ...............20-10 Latching Cable Shear Screw Location .........20-10 Attaching and Detaching Corn Head to Forage Harvester or Corn Husker ...............20-10

Retrofit Head to Pre 60 Series Combine Attaching Corn Head to Pre 60 Series Combine ........................................................25-1

Transporting Transporting Corn Head on a Trailer .............30-1

Operating Header General Information .......................................35-1 Starting in the Field ........................................35-1 Adjust Corn Head Properly ............................35-1 Drive and Operate Carefully ..........................35-1 Corn Head Engage/Disengage Drive ............35-2 Corn Head Drive Speeds ...............................35-2 50, 60 and 70 Series Combines with Variable Speed Feeder House .......................35-3 9400, 9410, 9500, 9510, 9600 and 9610 Combines With Variable-Belt-Drive Feeder House ................................................35-3 Combines With Fixed Speed Feeder House ............................................................35-4 Harvesting Corn With Weakened or Broken Stalks .................................................35-4 Harvesting Popcorn .......................................35-4 Gatherers .......................................................35-5 Raising and Removing Center Gatherer Shields and Points .........................................35-5 Lowering ACTIVE HEADER CONTROL Ground Sensors (Optional) ............................35-7 Raising and Tilting End Fenders and Points ..35-7 Ear Savers .....................................................35-8 Row Units ......................................................35-8 Stalk Rolls ......................................................35-9 Hydraulic Adjustable Deck Plates ..................35-9 Chopping Gear Cases (Optional) ................35-10 Removing, Flipping, and Installing Chopping Knife Blades ................................ 35-11 Auger ...........................................................35-12 Stubble Lights ..............................................35-12 Outer Gatherer Extensions ..........................35-12

Calibration and Programing When to Calibrate ..........................................40-1 Calibration Error Codes .................................40-1 Armrest Functions ..........................................40-1 Active Header Control Display .......................40-2 Deck Plate Control Display ............................40-3

01-2

Contents

Item Page Item Page Description of Automatic Header Height Control System ..............................................40-4 Height Sensing and Active Header Float Pressure Sensitivity (Automatic Functions) ....... 40-5 Manual Raise/Lower Speed (Manual Functions) ........................................40-6

Adjustments Adjusting and Leveling Gatherer Points ........45-1 Adjusting Trash Knives ..................................45-2 Adjusting Gatherer Chain Tension .................45-3 Adjusting Gatherer Chain Flights ...................45-3 Adjusting Deck Plates ....................................45-4 Adjust Row Spacing .......................................45-5 Adjusting Slip Clutches ..................................45-9 Adjusting Row Unit Drive Chain .....................45-9 Adjusting Row Unit Drive Sprockets With (ONLY) Fixed Speed Drive (Combines) ..................................................45-10 Adjusting Row Unit Drive Sprockets With (ONLY) Fixed Speed Drive (Forage Harvesters) ..................................... 45-11 Adjusting Row Unit Drive Sprockets With (ONLY) Fixed Speed Drive (Corn Huskers) ............................................45-12 Adjusting Auger ............................................45-12 12-Row Auger Adjustment Only ...................45-13 Coupling the Chain ......................................45-13 Adjusting Auger Drive Chain ........................45-14

Lubrication Corn Head Grease .........................................50-1 Grease ...........................................................50-1 Lubricant Storage ..........................................50-2 Alternative and Synthetic Lubricants .............50-2

Lubrication and Maintenance Hydraulic Cylinder Safety Stop ......................55-1 Lubrication Symbols ......................................55-2 Auger Floor Clean Out Door ..........................55-2 Annually or Every 200 Hours of Operation ....55-3 Every 1000 Hours of Operation .....................55-6

Troubleshooting Troubleshooting .............................................60-1 Active Header Control (AHC) .........................60-4

Service Hydraulic Cylinder Safety Stop ......................65-1 Remove and Install Stalk Rods ......................65-1 Reversing Gatherer Chains and Sprockets for Additional Wear.........................................65-4 Replacing Gatherer Chain .............................65-5 Remove and Install Oil Pan ...........................65-6 Wear Strips ....................................................65-7 Stubble Light Bulb Replacement ...................65-7 Header Warning Light Bulb Replacement ......65-8

Storage End of Season Service ..................................70-1 Beginning of Season Service .........................70-2

Specifications Specifications .................................................75-1 Serial Number ................................................75-2 Keep Proof of Ownership ...............................75-2 Keep Machines Secure ..................................75-2 Unified Inch Bolt and Screw Torque Values ...75-3 Metric Bolt and Screw Torque Values ............75-4

05-1

Corn Head Safety FeaturesCorn Head Safety Features

In addition to the safety features shown here, safety signs on the corn head, and safety messages and instruc-tions in the operator’s manual contribute to the safe operation of this corn head when combined with the care and concern of a capable operator.

A - Warning Lights B - Reflective Materials C - Safety Decals

05-2


10-1

Recognize Safety Information

This is a safety alert symbol. When you see this sym-bol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

DANGER

WARNING

CAUTION

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

Understand Signal Words

Safety

Wear Protective ClothingWear close fitting clothing and safety equipment ap-propriate to the job.

Prolonged exposure to loud noise can cause impair-ment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music head-phones while operating machine.

10-2

Safety

Follow Safety InstructionsCarefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and re-pair parts include the current safety signs Replace-ment safety signs are available from your dealer.

Learn how to operate the equipment and how to use controls properly. Do not let anyone operate without instruction.

Keep your equipment in proper working condition. Unauthorized modifications to the equipment may im-pair the function and/or safety and affect equipment life.

If you do not understand any part of this manual and need assistance, contact your dealer.

Prepare for EmergenciesBe prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your tele-phone.

Store Attachments SafelyStored attachments such as dual wheels, cage wheels, and loaders can fall and cause serious injury or death.

Securely store attachments and implements to pre-vent falling. Keep playing children and bystanders away from storage area.

10-3

Ballasting for Safe Ground Contact

Operating, steering and braking performance of the combine can be considerably affected by attachments which alter the center of gravity of the machine. To maintain safe ground contact, ballast the combine at the rear end as necessary. Observe the maximum permissible axle loads and total weights.

Lower harvesting unit to the ground.

Before leaving the combine, disengage harvesting unit and separator. Shut off engine and move gear shift lever to neutral. Apply parking brake, remove key and lock the operator’s cab.

Never leave combine unattended as long as engine is running.

Never leave the operator’s cab when driving.

Parking and Leaving the Combine

Avoid Contact With Moving PartsKeep hands, feet and clothing away from power driv-en parts. Never clean, lubricate or adjust machine when it is running.

Safety

10-4

Safety

Prevent collisions between other road users, slow moving tractors with attachments or towed equip-ment, and self-propelled machines on public roads. Frequently check for traffic from the rear, especially in turns, and use turn signal lights.

Use headlights, flashing warning lights, and turn sig-nals day and night. Follow local regulations for equip-ment lighting and marking. Keep lighting and marking visible, clean, and in good working order. Replace or repair lighting and marking that has been damaged or lost. An implement safety lighting kit is available from your dealer.

Road transport disconnect switch (A) must be in road position when transporting machine on roadway.

When road transport disconnect switch is pressed, indicator light (B) will turn ON indicating switch is in road position. Road transport disconnect switch will prevent the following functions:

• Header Height Resume • Header Height Sensing • CONTOUR MASTER • Reel Raise/Lower and Reel Fore/Aft • Unloading Auger • Auger Swing • Power Folding Auger (If Equipped) • Separator Engage • Header Engage • Header Raise/Lower

To reengage functions for field operation, press road transport disconnect switch again and indicator light will turn OFF allowing the desired function switches to operate again.

Road Transport Disconnect Switch (Black)

Use Safety Lights and Devices

10-5

Safety

Stay Clear of HeaderStalk rolls of the corn head, etc., cannot be complete-ly shielded by constructional measures due to their function. Always stay clear of these moving elements during operation! Always disengage header drive, shut off the engine and remove key before servicing or unclogging header.

Avoid TanglementTo avoid entanglement, do not feed crop material into machine by hand or attempt to manually unplug ma-chine while it is running. The stalk rolls can feed the crop material in faster than you can release your grip on the material.

Transport Combine With Header SafelyWhenever possible avoid transporting on public road-ways when the header is attached.

If the combine must be transported with the header attached, make sure that the flashing warning lights on the header are operating and the reflective mate-rial is clean and visible.

The use of a spotter or pilot vehicle is recommend-ed on busy, narrow or hilly roads and when crossing bridges.

Drive at a speed that is safe for conditions.

10-6

Safety

Stay Clear of Rotating DrivelinesEntanglement in backshaft rotating driveline can cause serious injury or death.

Keep driveline shields in place at all times.

Wear close fitting clothing. Stop the combine engine and be sure driveline is stopped before making ad-justments, connections, or cleaning out header or its drive components.

Practice Safe MaintenanceUnderstand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust engine while it is running. Keep hands, feet, and clothing from power-driven parts. Disengage all power and operate con-trols to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow en-gine to cool.

Securely support any engine elements that must be raised for service work.

Keep all parts in good condition and properly in-stalled. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on elec-trical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system com-ponents or welding on machine.

10-7

Safety

Guards and ShieldsKeep guards and shields in place at all times. Ensure that they are serviceable and installed correctly.

Always disengage main clutch, shut off engine and remove key before removing any guards or shields.

Keep hands, feet and clothing away from moving parts.

Service Machines SafelyTie long hair behind your head. Do not wear a neck-tie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

10-8

Support Machine ProperlyAlways lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, pro-vide secure support for them. If left in a raised po-sition, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator’s manual.

Safety

Avoid High Pressure FluidsEscaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before discon-necting hydraulic or other lines. Tighten all connec-tions before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Depart-ment in Moline, Illinois, U.S.A.

10-9

Safety

Remove Paint Before Welding or HeatingAvoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

• If you use solvent or paint stripper, remove strip-per with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where weld-ing will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

Avoid Heating Near Pressurized Fluid LinesFlammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, sol-dering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the imme-diate flame area.

10-10

Safety

Dispose of Waste ProperlyImproperly disposing of waste can threaten the envi-ronment and ecology. Potentially harmful waste used with Frontier equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regula-tions may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling cen-ter, or from your Frontier dealer.

Replace Safety SignsReplace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

15-1

Safety Decal LocationsSafety Decal Locations

15-2

Safety Decal Locations

Chopping Corn Head Safety Decal

20-1

Attaching and DetachingAttaching Corn Head to Feeder HouseIMPORTANT: See your combine operator’s man-ual for specific tires required when operating the header.

Latch pins are not to be actuated with header on the ground. If multi-coupler must be actuated with header on ground, unhook cable from handle.

1. Sound horn, start engine and lower feeder house.2. Drive combine slowly forward until feeder house is

centered in attachment frame opening.3. Raise platform completely, making sure two hooks

(A) on feeder house catch front side of main frame beam of platform.

4. Set parking brake, shut off engine, remove key and lower safety stop.

5. Remove cover (A) and clean multi-coupler face (B).

20-2

Attaching and Detaching

6. Open handle (A) and remove multi-coupler (B) from storage (C).

NOTE: To prevent damage to latching cable, a shear screw is attached to the handle. Attempts to actuate latching pins with header on ground will shear the screw on the handle. (See Extra Shear Screw Location later in this section.)

With header attached, latch pins should move freely through latch plate holes. If latch pins do not extend through the latch plates, make sure that the latching plates on the header are properly ad-justed.

7. Install multi-coupler (A) onto receptacle (B) and close handle (C).

20-3

Machines Equipped with Slide Lock Multi-couplers

IMPORTANT: Failure to slide lock plate through multi-coupler assembly could result in the header falling off while harvesting or transporting.

When multi-coupler handle is closed, slide lock plate (A) through multi-coupler latch assembly (B) and re-tain with quick-lock pin (C).


Machines Equipped with Button Lock Multi-couplers

IMPORTANT: Failure to close multi-coupler fully so button lock can engage could result in the header falling off while harvesting or transport-ing.

1. When multi-coupler handle is fully closed, button lock (A) will automatically lock couplers together.

Button Lock Equipped Latch

20-4


2. Latch pins (A) should move freely through latch plate holes in header when multi-coupler is latched. Latch plate (B) must make contact with bracket (C). Less clearance (D) should be maintained between bottom of plate and pin rather than top of plate (E) and pin. This may require latch plate to be flipped.

3. If adjustment is needed: Remove cap screws (F), flip plate (D) end for end and reinstall.

4. Tighten cap screws to M12 specification.

SpecificationM12 CapScrews — Torque ....................................130 N∙m (96 lb-ft)

20-5


5. Install multi-coupler (A) on platform storage posi-tion.

6. Remove telescoping shaft (A) from storage posi-tion and install onto feeder house backshaft, mak-ing sure quick attach collar locks fully.

Storage Position

20-6


Detaching Corn Head from Feeder House

CAUTION: Do not leave drive shafts on combine. Personal injury or machine damage may occur if feeder house is ac-cidentally engaged.

1. Disconnect telescoping drive shaft from feeder house at the quick disconnect coupler (A) on left-hand side of feeder house.

2. Place telescoping drive shaft in storage position (B).

IMPORTANT: Latch pins are not to be actuat-ed with header on the ground. If multi-coupler must be actuated with header on ground, un-hook cable from handle.

NOTE: Latch pins should be fully retracted when handle is all the way up against the stop. Adjust cable mounting if latch pins are not fully retracted (see Single Point Latching—Adjusting).

3. Remove quick-lock pin and slide lock plate through multi-coupler latch assembly.

4. Raise handle to disconnect multi-coupler.

5. Remove multi-coupler cover from storage position on header and place cover on combine multi-cou-pler.

6. Disconnect multi-coupler from combine and place in storage position (C).

7. Sound horn, start engine, lower feeder house until hooks (A) are below top beam of head, and drive combine slowly rearward.

20-7


Single Point Latching — AdjustingNOTE: CONTOUR MASTER Feeder House: Adjust-ments should only be made to cable at multi-coupler handle.

Level Land Feeder House: Adjustments should only be made to cable at multi-coupler handle, unless ca-ble is not centered at lower end (latch pin location). See Level Land Feeder HouseLower End Cable—Adjusting.

1. Open left-hand feeder house shield (A).

2. Loosen cable jam nuts (B).

IMPORTANT: Verify handle is against stop on multi-coupler. Failure to verify handle is against the stop will result in inaccurate pin dimensions and could result in the header fall-ing off while harvesting or transporting.

3. Rest multi-coupler handle against stop.

NOTE: Moving cable “up” in bracket pulls pin far-ther in.

Moving cable “down” in bracket pushes pin farther out.

4. Adjust cable in bracket as needed for proper pin adjustment:

• Left-hand latching pin should be flush to +/2 mm (A).

Left-Hand Latching Pin

20-8


5. Hold bottom jam nut (B) and tighten top jam nut (A).

IMPORTANT: Failure to verify pins are set to specified dimensions could result in the head-er falling off while harvesting or transporting.

6. Fully lower multi-coupler handle (A) and verify pins (B) (both sides) are set to specification. Readjust if not set to specification.

SpecificationFeeder HousePins — Distance .................45 — 52 mm (13/ 4 in. — 2 in.)

20-9


Level Land Feeder House Lower EndCable — AdjustingAdjustments should be made to the lower end of the latching cable if the threads (A) are not centered in the bracket (B).

Loosen jam nuts (C) and adjust cable so that threads are centered in bracket.

Tighten jam nuts.

Feeder House Latching Pins (Cleanout)If latch pins are hard to move, remove cap screws (A) and cleanout pin area. It may be necessary to fully tilt the feeder house frame in order to access these cap screws.

20-10


Feeder House Manual UnlatchingTo remove header if shear screw should fail, push latching pins (A) through latch plates and install M12 cap screw (B) in hole (C). Repeat on opposite side.

Latching Cable Shear Screw LocationIf shear screw (A) should break, remove and replace with extra shear screw (B). Three extra shear screws have been provided.

Attaching and Detaching Corn Head toForage Harvester or Corn HuskerFor attaching or detaching corn head on a forage har-vester or a corn husker, see the operator’s manual for that machine.

25-1

Retrofit Head to Pre 60 Series CombineAttaching Corn Head to Pre 60 Series CombineIn order to attach a corn head to an older combine conversion bundles are required. See your John Deere Dealer for the proper bundle(s).

IMPORTANT: Avoid damage to platform and feeder house, latch pins (A) (both sides) must be in the IN position before attaching header (as shown).

Slide stop bolt (B) in and then rotate up. If pins are in the OUT position, feeder house will be damaged when header is attached.

25-2


30-1

TransportingTransporting Corn Head on a Trailer

CAUTION: Follow local regulations re-garding width, lighting and marking.

IMPORTANT: Whenever possible avoid transport-ing the combine with the corn head attached. In-stead, transport the corn head on a truck or head-er trailer.

Follow the header trailer manufacturer’s recom-mendations regarding safe transport procedures. In absence of such instructions follow these guidelines:

• Do not transport at speeds greater than 32 km/h (20 mph) on a trailer not equipped with brakes and 40 km/h (25 mph) on a trailer equipped with brakes.

• Always attach a properly sized safety tow chain.

• Always make sure a slow moving vehicle em-blem is mounted to the rear of the trailer or header.

• Always make sure that the rear of the trailer is equipped with red reflectors, two red taillights and turn signals.

Reference combine Operator’s Manual for com-bine transporting procedures.

If equipped with ACTIVE HEADER HEIGHT CON-TROL (AHHC)™ ground sensors, the sensors

Points Folded for Transporting

must be placed in storage position to prevent equipment damage when folding points (see next page for procedures).

ACTIVE HEADER CONTROL is a trademark of Deere & Company

To reduce transport width, points should be in up-wards position (see Points Folded for Transport illus-tration).

1. Center Gatherer Shields Raise point (B) and latch (A).

30-2

Transporting

IMPORTANT: If equipped with ACTIVE HEADER HEIGHT CONTROL (AHHC) ground sensors, the sensors must be placed in storage position to prevent equipment damage when folding points.

2. Place in storage position.

Equipped with ACTIVE HEADER HEIGHT CON-TROL (AHHC): Rotate sensor arm (A) up into stor-age position and retain with storage lock pin (B).

3. Rotate header warning lights (A) rearward.

4. Outer Gatherer Shields Raise point until latch pin (A) engages. To lower, pull latch and lower point.

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Operating HeaderGeneral InformationThe gatherer points (A) are positioned between the rows of corn. Stalk rolls (B) grab the corn stalks and pull them rapidly down between the rolls.

When an ear of corn reaches the deck plate, the ear is prevented from going through because of the nar-row opening. The stalk rolls continue to pull on the stalk and snap the ear free of the stalk.

Gatherer chains (C) catch the ears and carry them to an auger (D) which delivers the ears to the feeder conveyor. The feeder conveyor delivers the ears to the threshing cylinder.

Starting in the FieldOperate the combine in a lower gear until you be-come familiar with the corn head.

After making several rounds, stop the corn head and shut off engine and remove key. Check all bearings for heating. All bolts must be tight and chains properly adjusted.

Adjust Corn Head ProperlyAfter making several rounds, check adjustments on corn head and combine. (See “ADJUSTMENTS”).

Drive and Operate CarefullyDrive carefully so the corn head will stay on the rows. Never force the corn head or combine to the point ofoverloading. Overloading can cause breakdowns. Start out in a lower gear and increase speed until you find the proper ground speed at which to operate.

Listen for slipping clutches or other unusual noises. If the corn head becomes plugged, clean it out by keep-ing engine at operating speed, but decrease ground speed until header has been cleared.

IMPORTANT: The forward movement of the com-bine must be approximately the same as the rear-ward movement of the gathering chain flights or plugging can result.

35-2

Operating Header

Corn Head Engage/Disengage DriveNOTE: To engage the header, operator must be in the operator seat before engaging the separator and head switches.

To engage header: • Switch road transport disconnect switch (A) to

field position. • Engage separator switch (B). • Engage header switch (C).

Header Engage Switch (9000 and 10 Series Combines)

Corn Head Drive SpeedsForward combine travel must be close to the same as rearward movement of gathering chain flights.

If ground speed is too fast, gathering chains will push stalks forward and knock off ears. If ground speed is too slow, gathering chains will jerk stalks back into the corn head, possibly shearing off stalks or knocking off ears.

35-3

Operating Header

50, 60 and 70 Series Combines withVariable Speed Feeder HouseThe corn head drive speed is varied by changing the speed of the lower feeder house shaft. Lower feeder house shaft speed is changed with reel switch (A) lo-cated on the multifunction control handle.

To operate reel switch, the road transport disconnect switch (B) must be in field position.

Push and hold the top of switch to increase speed, push and hold bottom of switch to decrease speed.

Engine and header must be running to adjust speed.

9400, 9410, 9500, 9510, 9600 and 9610Combines With Variable-Belt-DriveFeeder HouseCorn head drive speed is varied by changing speed of the lower feeder house shaft. Lower feeder house shaft speed is changed with the plus (+) or minus (-) switch located on the hydro handle.

Push and hold the bottom of switch to increase speed, push and hold top of switch to decrease speed.

Engine and header must be running to adjust speed.

Shaft speed of variable drive equipped feeder house ranges from approximately 630 to 780 RPM.

Use the following table as a guide in matching corn head speed to combine travel speed:

ApproximateCombine Travel Speed

ApproximateLower Feeder House

Shaft Speed

less than: 6.4 km/h (4.0 mph) 630 rpm 8.9 km/h (5.5 mph) 710 rpmgreater than: 11.3 km/h (7.0 mph) 780 rpm maximum

35-4

Operating Header

Harvesting Corn With Weakened orBroken StalksStalks and ears can be weakened by disease (stalk rot) or insects (corn borers), causing them to break off near the ground when contacted by corn head divider points and gatherer shields. This material is pushed into piles that prevent stalks from contacting the stalk rolls. Crop is lost and harvesting productivity is re-duced when this occurs.

The following is a list of possible solutions to these problems: • Reduce combine ground speed. • Increase corn head speed with the variable speed

feeder house. • Adjust deck plates as wide as possible without

allowing ears to contact the stalk rolls. • Remove ear savers. • Replace stalk rolls if flutes are badly worn.

Harvesting Popcorn • Adjust deck plates as close as possible • Check combine operator’s manual for correct set-

tings. • Raise cross auger so the largest diameter ear

passes between flighting and floor without con-tact.

• Decrease header backshaft speed.

Combines With Fixed Speed Feeder HouseRefer to adjustments Section for modifying header speed on fixed speed feeder house combine.

35-5

Operating Header

GatherersFor most conditions, operate front of gatherer points just touching the ground.

In muddy conditions, or in snow, raise header high enough to prevent scooping material into throat open-ing.

Adjust all points level with one another.

Raising and Removing Center GathererShields and Points

1. Loosen cap screw (A) on the rear of the gatherer shield and raise stop (B) to the vertical position.

NOTE: Do not over tighten cap screw (A).

SpecificationGatherer Shield CapScrew — Torque .........................................20 Nm (15 lb-ft)

35-6

Operating Header

2. Raise point and retain using pin (A). Pull latch bar (B) and lift point.

3. IF EQUIPPED: Disconnect ACTIVE HEADER CONTROL sensor wiring harness connector (C) from main wiring harness connector. Connector is located inside of the deck cover, near the through hole. Cut tie band attached to the rear of the cover, and then pull connector out to access.

CAUTION: The center shield and point as-sembly is heavy and awkward to handle.

4. Slide the gatherer shield to right-hand side until shield is free of support pins (D), lift off point and gatherer shield assembly.

35-7

Operating Header

Lowering ACTIVE HEADER CONTROLGround Sensors (Optional)Support sensor arm (A) and pull storage pin (B) out to unlock sensor arm.

Storage lock pin should remain in locked out position for field operation.

Raising and Tilting End Fenders and Points1. Release latch pin (A) and rotate to locked posi-

tion.2. Raise outer point until pin (B) latches.3. Release pins (C) and rotate gatherer shield and

point outward.

35-8

Operating Header

Row UnitsThe row unit houses the trash knives, gathering chains, deck plates, and stalk rolls. Ears of corn are snapped from the stalk and conveyed to the auger by the row unit.

Ear SaversEar savers (A) prevent loose ears from sliding over the gatherer chains to the ground.

In down corn, or if stalks tend to plug up at the gath-erer throat opening, remove ear savers. Retain ear savers and hardware.

In standing corn, replace ear savers to prevent ear loss.

Replace ear savers as follows:

Remove cap screws (B) attaching ear savers and re-move ear savers.

NOTE: When installing ear savers, torque cap screws to specification.

SpecificationCap Screws — Torque .............20 — 25 Nm (15 — 18 lb-ft)

35-9

Stalk RollsStalk rolls pull cornstalks down so the ears will be snapped off at the stalk and onto the deck plates.

To help you decide which stalk rolls are best suited for your needs, see the following guidelines.

Knife Stalk RollsAre recommended if your need is to cut and size corn stalks (10 16 in. length) at harvest for the following reasons: • Faster residue breakdown. • Earlier soil warm up and dry out. • Improved handling of residue by tillage and plant-

ing equipment, especially in high yielding corn (150 bu/ac plus).

• Desire to reduce passes needed for shredding, cutting or sizing stalks with other implements.

Hydraulic Adjustable Deck PlatesNOTE: To adjust or calibrate your deck plate, see your combine Operator’s Manual.

Hydraulic adjustable deck plate (A) allows operator to adjust deck plates within the cab for varying stalk and ear size to prevent grain loss from head.

Deck plates can be moved only when engine is run-ning and road transport disconnect switch is in field position.

Pressing reel forward switch opens deck plates and pressing reel aft switch closes deck plates.

• Knife stalk rolls perform well in all conditions. • Knife rolls work better in damp tough and high

moisture conditions. • Knife rolls also work better in heavy grass, vines

and weeds.

Operating Header

35-10

Operating Header

Chopping Gear Cases (Optional)Factory installed corn stalk choppers are available for model CH2208 header.

Chopping gear cases have two reservoirs that are filled with 80W90 GL5 oil from the factory.

IMPORTANT: Replacement gear cases purchased through service parts are shipped dry. Be sure to fill any replacement gear cases with oil to specifi-cation before operating machine.

Each reservoir is equipped with a drain plug and an oil check/fill plug that need to be removed to fill or drain the reservoirs.

Oil should be checked once a season or every 200 hours of operation (see LUBRICATION AND MAIN-TENANCE section).

Oil should be drained and replaced every 1000 hours of operation (see LUBRICATION AND MAINTE-NANCE section).

Item Measurement SpecificationRear Gear Case Reservoir (A) Capacity 325 mL (11 oz)

Front Gear Case Reservoir (B) Capacity 500 mL (16.9 oz)

35-11

Operating Header

Removing, Flipping, and InstallingChopping Knife Blades

CAUTION: Knives have two sharp cutting edges and can cause serious injury. Wear gloves when handling knives.

NOTE: Chopping knives are wear items. Knives can be flipped for extended knife wear. Worn, dull, or damaged knives are factors that affect corn head power consumption and stalk chopping quality, both of which can limit harvest speed. The expected wear life of chopping knives will vary with the operator’s harvest conditions and operation habits. Flip and re-place knives as needed to maintain acceptable stalk chopping ability & replace any excessively worn bush-ings and hardware.

NOTE: Chopping knife blades must be replaced in pairs on each chopping gear case.

1. Remove lock nuts (C), washers, bushings (D), and cap screws.

2. Remove knives (A) from between plate (B).

3. Inspect all hardware and bushings for excessive wear or damage and replace as necessary. Lock nuts can be reused when flipping blades. Lock nuts must be replaced when replacing knives.

4. Install knives using cap screws, bushings, wash-ers, and lock nuts. Tighten to specification.

SpecificationScrew — Torque .......................................130 Nm (96 lb-ft)

35-12

Operating Header

Stubble LightsLights up the area directly behind the corn head so the operator can see the height of cut during night-time harvesting.

Stubble lights can be tilted up or down, and can be twisted left and right.

Outer Gatherer ExtensionsExtensions (A) prevents ear loss over the sides of the low profile gatherer sheets.

When operating in conditions where the corn stalks are down, Lower the outer gatherer extensions for smooth stalk gathering action.

Extensions are incorporated into the end fender and can be raised and lowered.

1. Raise extension until pin (B) locks.

2. To lower extension push pin (B) in an lower exten-sion.

NOTE: Extension must be lowered to raise outer point.

AugerAuger (A) conveys crop material from the row units and directs crop material into the feeder house.

40-1

When to CalibrateNOTE: All Calibration: See calibrations for your Header in your Combine Operator’s Manual.

Calibration procedures must be performed before first use or if header height control sensor, deck plate posi-tion sensor or associated components are replaced.

• Header Calibration - LC1 (hdr). • CONTOUR MASTER Angle Sensor Calibration -

LC1 tilt (Optional).

• Hydraulic Adjustable Deck Plate - LC1 (Optional) on a 50 and 60 Series Combines Sensor Calibra-tion - dEc.

• Active Float Calibration - FLO.

NOTE: The condition causing the error must be cor-rected before the calibration can be continued.

If any errors occur during the calibration procedures, error codes will be displayed on the triple display ta-chometer, on 50 and 60 Series Combines and dis-played on the Command Center Display on a 70 Se-ries Combine.

Calibration Error CodesIMPORTANT: Condition(s) causing the error code must be corrected before the calibration proce-dure can continue.

If any error codes occur (ERxx) during the calibration procedures, call your Frontier dealer with the error code number.

Armrest FunctionsCommandCenter™ Armrest header functions: For complete information on each function see your Com-bine Operator’s Manual.

A — Header Engage and Feeder House Reverse Switch

B — Separator Engage Switch C — Cutterbar Pressure Adjust Switch D — Draper Belt Speed Adjust Switch E — Feeder House Rate/Sensitivity

Adjust Switch F — Road Transport Disconnect

Switch G — Header Height/HydraFlex™ Pres-

sure Control Dial H — Reel Speed or Belt Pickup Speed

Dial I — Selection Dial (Operating Adjust-

ments and Controls)

Calibration and Programing

40-2


Active Header Control DisplayNOTE: For complete information on each function and calibrations. Refer to your Combine Opera-tor’s Manual.

Header Height Sensing Button: allows the opera-tor to select the position of the header relative to the ground and return to that position automatically.

Header Height Sensing Button (HydraFlex): allows the operator to adjust the cutterbar ground pressure, or weight of the cutterbar, and return to that setting automatically. HydraFlex works in conjunction with header height sensing to maintain a header position relative to the ground, follow the ground contour, and return to that position automatically.

Header Height Resume Button: allows the operator to select the position of the feeder house relative to the machine and return to that position automatically.

Contour-Master Button: allows the operator to main-tain the header position relative to the ground. Sen-sors are used to determine the height at each end of the header. The header tilts to equalize the distances to the ground at each end of the header. If equipped with Header Height Sensing — HydraFlex (optional), the two systems work together to maintain the closest position of the cutterbar relative to the ground.

Reel Dial-A-Speed Button: allows the operator to automatic control of operating speed for reel or belt pickup headers. Operating speed will be a ratio of the machine ground speed to the reel or belt speed.

Active Header Float Button: allows a rigid header to be operated in contact with the ground and maintain a set contact pressure. The operator selects how firmly the header contacts the ground and returns to that pressure automatically.

Dial-A-Speed is a trademark of Deere & Company.

A — Active Header Control Display B — Header Height Sensing Button C — Header Height Resume Button D — ContourMaster Button E — Reel Dial-A-Speed ™ Button F — Active Header Float Button G — Reel Position Resume Button

40-3


Deck Plate Control DisplayReel fore/aft switch (A) on multifunction control han-dle allows operator to open and close adjustable deck plates.

System is active when: • Engine is running • Road transport disconnect switch (B) is in field

position

Press left-hand side of reel fore/aft switch (C) to open deck plates and right-hand side (D) to close deck plates to desired position.

Deck plate position icon (E) and deck plate opening (F) will appear on display. Deck plates have a range of 0 (minimum position) to 9 (maximum position).

Press and hold activations buttons 1,2, or 3 on multi-function control handle for two seconds to memorize current deck plate position. After deck plate position has been changed, press memory button to return to previous position.

40-4

Description of Automatic Header Height Control SystemAutomatic Header Height Control system compen-sates for uneven ground and controls horizontal and vertical positions of the header. The system continu-ously compares the preset position and the actual po-sition, thus keeping the header in the desired working position. Values are entered by the response rate ad-just and sensitivity adjust along with the selection dial located on armrest.

System Requirements: • Road transport disconnect switch must be in field

position. • Engine is running. • Header engaged. • Desired header control mode activated.

Lateral Tilt Adjustment — Two modes • Manual Adjust — hydraulic components are di-

rectly activated by multifunction control handle. • Automatic Adjust — parallel adjustments of the

header in relation to the ground are carried out by sensors on each end of header. This ensures that the distance between the header and the ground is equal on both the left-hand and right-hand sides.

Platform Height Adjustment — Four Modes • Manual Adjust — hydraulic components are di-

rectly activated by multifunction control handle. • Automatic height resume — platform can be set

to any position within the feeder house range. • Automatic height sensing — height of the plat-

form is maintained with height sensors attached to the platform. This ensures that header height is always constant over rough terrain.

• Automatic float control — machine maintains a constant header pressure with ground contact.

NOTE: It is possible to override automatic modes manually.


40-5

controls the speed of response for header move-ments when in automatic sensing and automatic float modes.

Operation:

NOTE: Press feeder house rate adjust and sensitivity adjust switch twice to adjust sensitivity settings (C).

Sensitivity setting will be shown on CommandCenterdisplay when adjusting. Settings are adjusted be-tween 0 to 100.

Press feeder house rate adjust and sensitivity adjust switch (A) twice and use selection dial (B) to adjust speed at which header follows ground contour.

Turn selection dial clockwise to increase response rate or counterclockwise to decrease response rate settings.

Height Sensing and Active Header Float Pressure Sensitivity (Automatic Functions)


40-6

controls response rate of header raise/lower functions for manual control or when in automatic height resume mode.

Operation:

NOTE: Press feeder house rate adjust and sensitivity adjust switch once to adjust rate settings (C).

Rate setting will be shown on CommandCenter dis-play when adjusting. Settings are adjusted between 0 to 100.

Press feeder house rate adjust and sensitivity adjust switch (A) once and use selection dial (B) to adjust rate at which header will react when being raised or lowered.

Turn selection dial clockwise to increase response rate or counterclockwise to decrease response rate settings (C).

Manual Raise/Lower Speed (Manual Functions)


45-1

AdjustmentsAdjusting and Leveling Gatherer Points

CAUTION: Raise corn head until points are off of the ground, shut off engine, and remove key.

Set one gatherer point to an appropriate height. Set remaining points to same height.

1. Raise point (A) and lock latch (B).

2. Pull spring locking pin (C) and adjust height using location holes (D).

3. The points can also be fine adjusted by loosen-ing jam nut (E) and adjusting cap screw (F) up or down.

45-2

Adjustments

Adjusting Trash KnivesTrash knives prevent weeds and trash from wrapping around stalk rolls.

Trash knives must be set as close as possible to rolls without striking the flutes.

1. Loosen four cap screws (B).

2. Adjust trash knife (C) so that gap (A) between knife roll is within specification.

SpecificationTrash knife roll toStalk-Roll-FluteGap — Gap ..............................................1.5 mm (1/16 in.)

3. Tighten cap screws (B) to specification.

SpecificationTrash Knife MountingCap screws — Torque ..............................130 Nm (96 lb-ft)

4. Verify stalk roll spiral (D) (front of roll) and stalk roll fin (E) (rear of roll) clear the trash knife when rotated.

5. Repeat procedure on opposite trash knife and for remaining row units.

45-3

Adjustments

Adjusting Gatherer Chain TensionGatherer chain tension is maintained by a spring-loaded tightener. The spring is shielded by a spacer tube (A) that also serves as a stop to prevent the idler sprocket (B) from retracting too far.

To increase gatherer chain tension, loosen nut (C) and tighten bolt (D).

To prevent chain from running off idler sprocket, main-tain a 4.8 mm (3/16 in.) maximum space between spacer tube (A) and washer (E).

Adjusting Gatherer Chain FlightsGathering chains are assembled at the factory with the chain flights (A) staggered between one another.

IMPORTANT: Be careful to avoid rocks and other obstructions in the row when running gatherers close to the ground.

1. Remove center shield.

2. Turn nut (A) until it is against leg of idler support strap (B).

3. Loosen bolt (C) until nut (D) disengages.

45-4

Adjustments

4. Lift chain off sprocket (A) and rotate chain until flights (B) are uniformly spaced.

5. Turn bolt (C) into nut (D) and tighten bolt until a 4.8 mm (3/16in.) maximum space between spacer tube (E) and washer (F).

6. Screw nut (G) tight against idler assembly.

Adjusting Deck Plates

NOTE: Deck plates are factory set.

1. Set deck plates to closed position (cylinder (A) fully extended). Verify left-hand side deck plates are in the closed position and reset and tighten clamp if necessary.

2. Clamp (B) should close and crimp tie bar when hardware is tightened. Install pivot arms on re-maining row units.

45-5

Adjustments

3. Loosen cap screws (A) retaining right-hand side deck plate to row unit frame.

4. Set front spacing (B) to 18 mm (23/32 in.) and rear spacing (C) to 20 mm (25/32 in.).

5. Tighten cap screws to specification.

SpecificationDeck Plate CapScrews — Torque .......................................95 Nm (70 lb-ft)

Adjust Row Spacing

CAUTION: When working under the corn head, always place the hydraulic cylinder safety stop in safety position to prevent header from lowering.

ROW SPACING

Corn Head cm in.CH2112 91.4, 96.5 36, 38CH2208 91.4, 96.5 36, 38

1. Remove and retain attaching hardware (A) and row unit drive shield (B).

2. Remove gatherer shields and points. (See Rais-ing and Removing Center Gatherer Shields and Points in the Operating Header section for proce-dure.)

NOTE: Row unit spacing cannot be changed on the CH2112. A different frame and augers are used for 36” and 38” spacing.

45-6

Adjustments

3. Remove cap screws (B), shield (C) and support (A).

NOTE: Shields (C) are different for 36” and 38” row spacing. See the Parts Catalog for correct part numbers for desired row spacing.

NOTE: To slide row units to desired location, with correct lifting devise lift and support under row unit skid plates keeping weight of unit on main frame.

4. Loosen bolts (A) of center two row units. Move both row units an equal distance to correct row spacing. Then move to the next outer row unit. Loosen bolts and move unit to the desired row spacing and continue until all row units are spaced correctly. Torque unit attaching bolts to specifica-tion.

SpecificationUnit AttachingBolts — Torque .......................................310 Nm (229 lb-ft)

Replace the tubes (D) used for latching the points to the row units. See the Parts Catalog for correct part numbers for desired row spacing.

A

C

B

D

45-7

5. Position row unit shield and gatherer shield support for desired row spacing and reinstall cap screws (B) in shield (C) and gatherer shield support (A).

SpecificationGatherer ShieldSupport — Torque ......................................70 Nm (52 lb-ft)

6. Reinstall shields and points on row units.

7. Connect sensor wire harness (if equipped) and push connector into hole of deck cover. Retain harness at yellow tape marks on harness to en-sure proper slack for raising points.

8. Reinstall row unit drive shield.

Adjustments

A

C

B

9. Replace outer strippers (A) and gap adjusters (B). See the Parts Catalog for correct part numbers for desired row spacing. A

B

45-8

Adjustments

10. If converting to 36” spacing, install debris shields (B). See the Parts Catalog for correct part num-bers for desired row spacing.

11. If converting to 36” spacing, install additional angle (A) and washer (B) on LH outer chopping curtain. See the Parts Catalog for correct part numbers for desired row spacing.

A

A

A

A

B

45-9

Adjustments

Adjusting Slip Clutches (CH2112 only)Slip clutches protect the corn head drives. Each row unit drive and auger drive has a slip clutch.

All slip clutches are properly adjusted at the factory. The only time slip clutches will require adjusting is when they are disassembled for service. The length of the row unit slip clutch spring (A), when correctly adjusted, must be 66 mm (25/8 in.). Chopping corn units and auger drive slip clutch are not adjustable.

IMPORTANT: Do not tighten nuts to the point where the clutch will not slip. The two nuts used to compress the spring must be jammed together. Torque to specifications. Grease thrust washer but do not grease clutch facings.

SpecificationSlip Clutch JamNuts — Torque ..........................................125 Nm (92 lb-ft)

NOTE: 12 row corn heads cross augers aredriven from both sides.

Adjusting Row Unit Drive Chain1. Remove cap screws (A) and cover (B).

NOTE: An overtightened chain will cause undue chain wear. Row unit chain is a continuous chain without a connector link.

2. Adjust tension on drive chain (B) using tensioner (A). Lower chain strand should have play in chain with movement of 10 mm up and 10 mm down. Tighten cap screws to specifications.

SpecificationTightener CapScrews — Torque .......................................90 Nm (66 lb-ft)

3. Reinstall cover with retained capscrews.

45-10

Adjustments

Adjusting Row Unit Drive Sprockets With (ONLY) Fixed Speed Drive (Combines)

IMPORTANT: Changing corn head sprockets with a variable speed feeder house can result in the corn head over speeding, resulting in machine damage. Front driven shaft should never exceed 715 rpm.

Models CH2112 and CH2208 are driven from both sides of the head with a 30-tooth driver and 33-tooth driven sprockets standard equipment.

Chopping corn head models are driven with a 24-tooth driver and 27-tooth driven sprockets.

NOTE: Drain oil and remove pan before changing or adjusting sprockets, see Remove/Install Oil and Pan in Service section.

When operating at increased ground speeds, install small sprocket on driven shafts and large sprocket on drive shafts.

When Combining Non Chopping Choppingat: Corn Head Corn Head

Sprocket Sprocket Driver Driven Driver DrivenUp to 7 km/h 30-tooth 33-tooth 24-tooth 27-tooth(Up to 4 mph)

Over 7 km/h 33-tooth 30-tooth 27-tooth 24-tooth(4 mph)

Adjust tightener so chain will operate without climbing or jumping sprockets.

The following chart gives the approximate combine travel speed that is used with each sprocket combi-nation.

NOTE: Recommended travel speed in chart is based on average field conditions. Your particular field con-dition may differ and determine which sprocket must be used. Front Driven shaft should never exceed 715 rpm. Corn head running higher than 715 rpm can re-sult in machine damage.

NOTE: FIXED SPEED COMBINE ONLY — The sprockets are set from the factory 30T Driver and 33T Driven for non-chopping and 24T Driver and 27T Driven for chopping. These sprockets must NOT be changed for variable speed combines.

45-11

Adjustments

Adjusting Row Unit Drive Sprockets With (ONLY) Fixed Speed Drive (Forage Harvesters)

IMPORTANT: Front Driven shaft should never ex-ceed 715 rpm. May result in machine damage.

8 and 12 row corn heads are driven from both sides which include two 30-tooth driver and two 33-tooth driven sprockets as standard equipment.


For maximum operating speed, install large sprockets on drive shafts and small sprocket on driven shaft.

Fixed Speed Forage Harvesters Only

When changing sprocket location, secure sprockets to shafts and align sprockets for smooth operation.

Adjust tightener so chain will operate without climbing or jumping sprockets.

The following chart gives the approximate harvester travel speed that must be used with each sprocket combination.

NOTE: Recommended travel speed in chart is based on average field conditions. Your particular field con-dition may differ and determine which sprocket must be used.

Adapter PlateSprocket (Drive)

30-tooth

33-tooth

Corn Head ShaftSprocket (Driven)

33-tooth

30-tooth

Front Corn HeadShaft Speed@ 2100 Engine rpm

410

495

Approx. SuggestedGround Speed

Under 3 mph(5 km/h)

3 - 4 mph(5 - 7 km/h)

CH2112 and CH2208 Corn Heads

45-12

Adjustments

Adjusting Row Unit Drive Sprockets With(ONLY) Fixed Speed Drive (Corn Huskers)

IMPORTANT: Front driven shaft should never ex-ceed 715 rpm. May result in machine damage.


Install 33-tooth sprocket on drive shaft and 30-tooth sprocket on driven shaft.

When changing sprocket location, secure sprockets to shafts and align sprockets for smooth operation.

Adjust tightener so drive chain will operate without climbing or jumping sprockets.

Adjusting Auger

CAUTION: Keep safety shields in place.

1. Both sides of corn head main frame and auger bearing carriers (A) are slotted for adjusting auger. Auger can be adjusted up and down for clearance between auger flighting and floor.

2. Keep auger adjusted down in most conditions. Raise auger to prevent ear damage in popcorn and food grade corn.

3. In normal conditions, keep a minimum of 6 mm (1/4 in.) clearance between auger and the lower adjustable auger stripper.

4. In normal conditions, keep a minimum of 32 mm (11/4 in.) clearance between auger flighting and bottom of floor.

5. Bearing carriers can be removed and auger lifted and bolts install to upper slotted holes on each side to raise auger off of floor 76 mm (3 in.) for use in food corn.

45-13

Adjustments

12-Row Auger Adjustment Only

Adjust the auger height and fore-and-aft as follows:

1. Loosen three flange nuts (A).

2. Loosen nut (B).

3. Adjust nut (C) to move auger up or down.

4. Move auger fore-and-aft as necessary according to specifications.

IMPORTANT: There must be 22 mm (7/8 in.) clearance between auger flighting and floor and a 6 mm (1/4 in.) clearance between auger flighting and stripper.

SpecificationAuger Flighting andFloor — Clearance ......................................22 mm (7/8 in.)

Auger Flighting andStripper — Clearance ....................................6 mm (1/4 in.)

5. If raising auger off of the floor 76 mm (3 in.) for use in food corn, remove carriage bolts (D) and raise auger to align slots (E) with top slots (F). Install carriage bolts and retain with nuts.

6. Tighten all nuts to specification

SpecificationNuts — Torque ............................................90 Nm (66 lb-ft)

Coupling the ChainWhen securing a chain coupler link, closed end of spring lock must face in direction of chain travel as shown with bold arrow.

45-14

Adjustments

Adjusting Auger Drive Chain1. Remove cap screws (A) and cover (B).

2. Loosen nuts (A). Push on adjusting plate (B) to adjust chain tension.

3. Tighten nuts (A) to specification.

SpecificationNuts (A) — Torque ......................................90 Nm (66 lb-ft)

NOTE: An overtightened chain will cause undue chain wear. Adjust chain tension so that the slack side movement is 10 mm (3/8 in.) up and 10 mm (3/8 in.) down.

50-1

LubricationCorn Head GreaseJohn Deere CORN HEAD GREASE is recommended for the corn head row unit gear cases.

You may also use SAE Multipurpose Grease with Ex-treme Pressure (EP) Performance and meeting NLGI Consistency Number 0.

GreaseUse grease based on NLGI consistency numbers and the expected air temperature range during the ser-vice interval.

The following grease is recommended:• John Deere SD POLYUREA GREASE (TY6341)

Other greases may be used if they meet the following:• NLGI Performance Classification GCLB

IMPORTANT: Some types of grease thicken and are not compatible with others.

If grease fitting is missing, replace immediately. Clean fittings thoroughly before using grease gun.

Product Number

TY6341

DescriptionMultipurpose grease. High-Temperature Extreme Pressure Grease, especially effective in rolling contact applications.

50-2

Lubrication

Lubricant StorageYour equipment can operate at top efficiency only when clean lubricants are used.

Use clean containers to handle all lubricants.

Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other

contamination. Store containers on their side to avoid water and dirt accumulation.

Make certain that all containers are properly marked to identify their contents.

Properly dispose of all old containers and any residu-al lubricant they may contain.

Alternative and Synthetic LubricantsConditions in certain geographical areas may require lubricant recommendations different from those print-ed in this manual.

Some John Deere brand coolants and lubricants may not be available in your location.

Consult your John Deere dealer to obtain information and recommendations.

Synthetic lubricants may be used if they meet the per-formance requirements as shown in this manual.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils.

Re-refined base stock products may be used if the fin-ished lubricant meets the performance requirements.

55-1

Lubrication and MaintenanceHydraulic Cylinder Safety Stop


1. Start engine, raise feeder house and fully extend hydraulic cylinder to place safety stop in safety posi-tion.

2. (6620, 7720 and 8820 Combines) Disconnect sup-port chain from safety stop (A) and lower safety stop onto the cylinder rod.

3. (9400, 9500, 9600, 10 Series, and 50 Series Com-bines) Raise safety stop (A) from storage position and lower it down onto the cylinder rod.

After completing work on the corn head, place safetystop in storage position.

55-2

Lubrication and Maintenance

Lubrication Symbols

CAUTION: Never lubricate or service corn head while combine engine is run-ning. Turn off Engine, remove key, and set safety stops.

Lubricate with John Deere Multipurpose SD Polyurea High Temperature/Extreme Pres-

sure lubricant or an equal SAE Multipurpose High Temperature Grease with Extreme Pressure (EP) performance at hours shown on the symbol.

Lubricate with John Deere SAE 30 oil or heavier oil at hourly intervals indicated on the symbols.

Lubricate with John Deere corn head grease (type “O” [zero] extreme pressure) at hourly

intervals indicated on the symbols. The lubricant is available in a 0.4 kg (141/ 2 oz) tube AN102562. Wipe away all grease and dirt before removing in-spection plugs. Wipe grease fittings clean before lubricating.

IMPORTANT: Recommended service intervals are for average conditions. Service MORE OFTEN if corn head is operated under adverse conditions.

Auger Floor Clean Out Door1. Release latch (A) and open door (B).

2. Clean auger floor using clean out door on both sides of corn head.

3. Make sure door is fully latched before moving ma-chine.

55-3


Annually or Every 200 Hours of Operation1. Grease header drive shafts. Rotate shield as needed to access grease fitting.

2. Inspect and adjust the following; • Row Unit Drive Chain(s) • Auger Drive Chain • Row Unit Gatherer Chains (See Adjustments section for procedures.)

IMPORTANT: Keep oil level to specification toprevent excessive chain wear.

3. Replace oil in the drive chains (both sides of head) annually or every 200 hours of operation.

SpecificationDrive Chain Oil — Capacity ......................... 0.9 L (0.95 qt.)

a. Raise head and engage safety stop. b. Operate head to warm oil prior to draining. c. Remove plug (C) and lower header to drain

oil. d. Raise head and engage safety stop. e. Install plug. f. Lower header onto flat level ground and re-

move access door (B) and check plug (A). g. Add SAE 80/90 gear lube through access door

until level with the bottom of check plug (A). Ap-proximate capacity is 0.9 L (.95 qt.).

h. Install access door and check plug.

55-4


4. Check row unit gear case grease annually or every 200 hours of operation.

NOTE: Row unit gear case grease must be warm with header raised to obtain accurate readings on dipstick.

a. Operate header to warm row unit grease. b. Raise header and lower safety stop. c. Raise row unit shield. d. Clean area around inspection plug/dipstick

(A) to avoid dirt and debris from entering gear case.

e. Remove dipstick and wipe off grease. f. Insert dipstick until bottom of dipstick threads

rest on top of gear case recess (B). g. Remove and observe grease level on dipstick. h. If level is below full mark (C), add John Deere

Corn Head Grease through grease fitting (D) until level with mark.

IMPORTANT: Do not overfill gear case. 0.42 L (1 tube) of grease is required to fill gear case from minimum mark (E) to full mark (C). The amount of grease to add at other levels is pro-portional.

i. Install dipstick and operate header again to warm new grease as necessary to obtain ac-curate reading.

55-5


5. Check gear case oil (if equipped) annually or ev-ery 200 hours of operation.

NOTE: Chopping corn head gear cases must be warm with header raised to verify accurate oil level.

a. Raise header and lower safety stop.

b. Remove check/fill plug (A) at the rear of the gear case on each row. Oil level should be at the bottom of the check/fill plug hole. Add TY6296 80W 90 GL5 gear lube as necessary to obtain correct level.

Reinstall check/fill plug.

c. Remove check/fill plug (B) at the front of the gear case on each row. Oil level should be at the bottom of the check/fill plug hole. Add TY6296 80W 90 GL5 gear lube as necessary to obtain correct level.

Reinstall check/fill plug.

NOTE: 12 row chopping corn heads are driven from both sides of the head and requires two drive clutches.

6. Chopping Corn Head ONLY: Grease drive clutch fitting (A) annually or every 200 hours of opera-tion.

Chopping Corn Head Only

55-6


Every 1000 Hours of OperationNOTE: Drain and refill chopping gear case oil every 1000 hours.

Chopping corn head gear cases must be warm with header raised to drain and refill oil.

1. Raise header and engage safety stop.

2. Set parking brake, shut OFF engine and remove key.

3. Place a proper container under machine. Remove drain plug (A) at the rear of the gear case and drain plug (B) at the front of the gear case.

4. After oil has drained reinstall plugs.

5. Remove check/fill plug (C) at the rear of the gear case and check/fill plug (D) at the front of the gear case. Add TY6296 80W 90 GL5 Gear Lube to front and rear gear cases until level with the bottom of check/fill plug holes (C and D). Install plugs.

SpecificationRear GearCase — Capacity........................................325 mL (11 oz.)

SpecificationFront GearCase — Capacity..................................... 500 mL (16.9 qt.)

60-1

TroubleshootingTroubleshootingThe majority of corn head operating problems can be traced to improper adjustment. The following trouble shooting chart will help you when problems develop by suggesting a probable cause and the recommend-ed remedy. Make certain when you are trying to solve a problem, that the source does not come from some place other than where the problem exists.

60-2

Troubleshooting

Symptom Problem Solution

Loss of ear corn in the field.

Ear shelling at stalk rolls.

Shelled corn coming out rear of combine.

Ears sliding out through the throat.

Point tips set too high.

Ground speed too fast or too slow.

Not picking planter rows.

Row units not centered on rows.

Ears sliding out over gatherer chains.

Gatherer chain speed too fast or too slow.

Deck plates not adjusted correctly.

Machine operating too high.

Excessive trash intake from corn head.

Ear savers worn out.

Point tips set too high.

Adjust points so tips lightly touchground when row unit skid plate is 1 inch above ground.

When picking low hanging ears, raise front tip of gatherer points and run corn head with the skids close to the ground.

Operate at a speed to meet field and ground conditions. Too much ground speed can bend stalks for-ward and cause ears to fall ahead of gatherer chains. Slow ground speed can cause gatherer chains to jerk stalks and snap off ears caus-ing ears to slide off header.

Operate at a speed where gatherer chains help guide stalks into the rolls.

Follow planted rows to minimize ear loss.

Adjust corn head row spacing to equal row spacing of corn in field.

Replace worn ear savers or reinstall previously removed ear savers.

Change speed of variable speed feeder house or increase ground speed.

Adjust deck plates. Reduce gap be-tween deck plates.

Raise point tip and run head lower.

Increase variable drive speed or fixed drive speed.

Open deck plate spacing on corn head.

Replace ear savers.

60-3

Troubleshooting


Pulling up corn stalks.

Plugging

Loss of ear corn from weakened or broken stalks. Problem is caused by disease (stalk rot) or insects (corn borers).

Deck plates set too close together.

Traveling too fast for gathering speed.

Gatherer chain flights digging intocornstalk roots.Corn too dry or worn.

Worn stalk rolls.

Stalks breaking in stalk rolls or deck plates.

Trash winds around trash rolls.

Loose gathering chains.

Not picking planter rows.

Ground speed too fast, causing ma-terial to overrun corn head.

Material not flowing with auger.

Corn stalks plugging in gatherer throat opening.Worn stalk rolls.

Contact of stalk with ear savers.

Ground speed too fast.

Feeder house speed incorrect.

Worn stalk rolls.

Gradually open deck plates until stalks feed through rolls more freely.

Slow down to meet crop conditions or increase row unit drive speed.

Lower point tip and run head higher.

Remove ear savers.

Replace stalk rolls.

Adjust opening of deck plates. Alsobe sure deck plates are set equallyand centered over center of rolls.

Set trash knives closer to stalk rolls.

Check gathering chain mechanism.

Follow the rows to minimize ear loss.

Operate at a speed to meet yield and ground conditions. Faster speed causes plugging.

Check auger housing for obstruc-tions and roughness. Check auger for 22 mm (7/8 in.) clearance be-tween auger flight and floor. Check auger for 6 mm (1/4 in.) clearance between auger flighting and strip-per.

Remove ear savers.

Replace worn stalk rolls.

Remove ear savers.

Reduce ground speed.

Find the correct speed for your conditions by trying different feeder house speeds.

Worn stalk rolls. Replace stalk rolls.

60-4

Troubleshooting


Active Header Control (AHC)Will not operate.

Active Header ControlLowers but will not raise.

Active Header ControlRaises but will not lower.

System cycles or hunts.

System fails intermittently after man-ually raising header over obstacle.

Header raises or lowers too slow or too fast.

Manual raise or lower will not work.

Active Header Control (AHC) unit not enabled.

Feeder house to connector not con-nected or loose.

Header sensor not properly con-nected or damaged.

Defective Active Header Control re-lay or Active Header Control card.

Defective Active Header Control re-lay or Active Header Control card.

Control shaft restricted.

Auto drop rate valve closed.

Incorrect drop rate adjustment.

Incorrect accumulator setting.

System was de-activated.

Incorrect drop rate adjustment.

In-line valve problem.

See your Frontier dealer.

Enable Active Header Control mode that is desired in cornerpost display unit.

Connect properly.

Connect or repair sensor.



Check for restriction.

Adjust in-line valve.

Adjust in-line valve.

See your combine Operator’s Manual.

To reactivate, press activation but-ton in multifunction control handle.

Adjust valve stack drop rate.


Active Header Control (AHC)

65-1

ServiceHydraulic Cylinder Safety Stop


1. Start engine, raise feeder house and fully extend hydraulic cylinder to place safety stop in safety posi-tion.

2. (6620, 7720 and 8820 Combines) Disconnect sup-port chain from safety stop (A) and lower safety stop onto the cylinder rod.

3. (9400, 9500, 9600, 10 Series, and 50 Series Com-bines) Raise safety stop (A) from storage position and lower it down onto the cylinder rod.

After completing work on the corn head, place safety stop in storage position.

Remove and Install Stalk Rolls

CAUTION: Lower hydraulic cylinder safe-ty stop before working under corn head..

1. Remove cap screws (B), washers, and trash knife (A) from underside of row unit frame.

65-2

Service

NOTE: Stalk rolls will turn when attempting to re-move nut (A). Place a pry bar between the stalk roll and row unit frame to prevent stalk rolls from turning.

2. Remove and discard nut (A)

3. Stalk rolls can typically be pulled off by hand. If unable to do so locate the two ribs (A) on stalk roll. Remove stalk roll from shaft attaching a 2-jaw puller to ribs.

4. Shaft taper should be free of rust and dirt. Inspect stalk rolls for wear or damage.

65-3

Service

IMPORTANT: Stalk roll spherical nut (A) con-tains a pre-applied thread locking patch (B) and cannot be reused. A replacement nut must be purchased from Frontier Service Parts.

5. Align splines on stalk roll and shaft and install stalk roll.

6. Install replacement spherical nut (A) and tighten to specification.

SpecificationStalk Roll SphericalNut — Torque .........................................400 Nm (295 lb-ft)

7. Install trash knife (A) and retain using four washers and cap screws (B).

8. Adjust trash knives. (See ADJUSTING TRASH KNIVES in ADJUSTMENT section.

9. Repeat procedure on opposite stalk roll.

65-4

Service

Reversing Gatherer Chains and Sprockets for Additional WearThe gatherer chains and sprockets can be reversed for additional wear. This should be done to all row units at the same time. To reverse the chains and sprockets:

1. Release tension on gatherer chains and remove chains.

2. Remove rear sprockets (A) and (B).

3. Install sprocket (A) on row unit (D).

4. Install sprocket (B) on row unit (C).

5. Remove sprockets (E and F).

6. Install sprocket (E) on row unit (D).

7. Install sprocket (F) on row unit (C).

8. Turn gatherer chain (G) over and install on row unit (C).

9. Turn gatherer chain (H) over and install on row unit (D).

65-5

Service

Replacing Gatherer Chain

CAUTION: Raise corn head, turn engine off, remove key, and lower safety stop be-fore working under header.

NOTE: Gatherer chains have chrome pins for longer wear life. Black pin or chrome pin chains are available from your John Deere dealer.

If gatherer chain breaks, or is badly worn, replace with a new chain.

Gatherer chains can be removed for servicing parts of the gatherer mechanism without disconnecting the chain.

CAUTION: Never service any part of the mechanism or idler sprocket until you have nut (A) tight against leg of idler sup-port strap (B).

1. Turn nut (A) until it is against leg of idler support strap (B), to release gatherer chain tension.

2. Loosen bolt (C) if necessary until tension is off chain.

3. Remove gatherer chain (D).

65-6

Service

Remove and Install Oil PanNOTE: Capture fluid in a clean container. Dispose of oil properly, do not reuse.

1. Remove drain plug (A).

IMPORTANT: Avoid damage to reusable seal on pan. Do not use sharp objects to pry between pan and corn head.

2. Remove cap screws and washers (B) and oil pan (C).

NOTE: When retaining pan with cap screws, start

in center and move outward.

3. Reinstall drain plug (A).

4. Clean all dirt and oil from side sheet where oil pan (C) is mounted. Reinstall oil pan with cap screws and washers (B).

65-7

Service

5. Remove check plug (A) and access door (B).

IMPORTANT: Oil level should be checked with corn head on combine and row unit skids touching ground (approximately a 25 degree angle).

6. Add SAE 80/90 gear lube through access door un-til level with bottom of check plug (A).

7. Install plug and access door.

SpecificationOil Pan — Capacity .......................................... 0.9 L (1 qt.)

Wear Strips1. Remove nut and washer (A).

2. Remove bolt and washer (B).

3. Remove wear strip (C) and install new wear strip in reverse order.

SpecificationWear Strip Nut — Torque ........................10 Nm (7.38 lb-ft)

Stubble Light Bulb Replacement1. Unplug wire harness from light.

NOTE: DO NOT touch bulb with bare fingers, oil or water.

2. Twist connector on light assembly 90 degrees and pull out and install new bulb.

3. Reinstall in reverse order of removal.

65-8

Service

Header Warning Light Bulb ReplacementNOTE: Use a flat-blade screwdriver.

Carefully, pry off lens (A) from light.

Push bulb (B) in and turn to remove.

Install new bulb.

Press lens back onto light housing.

70-1

StorageEnd of Season Service

IMPORTANT: Do not use high pressure washer spray directly on bearings or any other area that might be damaged by water. High pressure water can get past most seals and cause damage. Dry these areas, then lube and run combine.

CAUTION: Support the corn head with ei-ther the hydraulic cylinder safety stop or with blocks, or lower it to ground level.

1. Clean the corn head thoroughly. Chaff and dirt will draw moisture and cause rust.

2. Lubricate the corn head. Grease the threads on adjusting bolts.

3. Paint all parts from which paint has worn.

4. Use a polymer protectorate on the points, deck covers and end fenders.

5. If possible, shelter the corn head in a dry place.

6. Order repair parts needed for next season.

70-2

Storage

Beginning of Season Service1. Clean the corn head thoroughly.

2. Adjust gatherer chains to proper tension.

3. Adjust chains to proper tension.

4. Lubricate corn head completely.

5. Go over complete corn head and see that all bolts are tight and cotter pins are spread.

6. Run corn head at half speed for a few minutes. Check bearings for overheating or excessive looseness.

7. Review your operator’s manual.

75-1

SpecificationsSpecificationsSpecifications given in the manual are intended for service only and do not include normal factory manu-facturing tolerances.

NOTE: Specifications and design subject to change without notice.

Gatherer Points Low profile floating type hinged above gatherer chains

Center and Outer Gatherers Hinged, quick-removableGatherer Chains Heavy duty 620 endless steel roller chain with

chromed pins (no master connecting link)Minimum Clearance Between Gatherer Chains and Ground

32 mm (1-1/ 4 in.)

Row Unit Drive Enclosed gear box with gears submerged in lubricant; driven by single input hex shaft

Gatherer Chain Adjustment Spring loaded self-adjusting

Stalk Rolls Spiral pointed, knife-type (2 per row unit)Deck Plate Adjustment Hydraulic AdjustedSlip Clutch CH2112 - One per row unit

CH2208 - Two per row unitTrash Knives Full length one piece heat-treated steel

Approximate Overall Width for Storage:Model Header ID Width mm (in.)CH2112 12R36 11066.20 mm (435.68 in.)CH2112 12R38 11675.80 mm (459.68 in.)CH2208 8R36 7615.25 mm (299.81)CH2208 8R38 7615.25 mm (299.81)

Approximate Overall Length for Storage(All Corn Heads):Points in operating position 3000 mm (9 ft 10 in.)Points folded up (service position) 2400 mm (7 ft 11 in.)

Approximate Shipping Weight of Corn Head (Includes Shipping Skid)

Non-Chopping Corn HeadModel Header ID Weight kg (lb.)CH2112 12R36 4332.79 kg (9552 lbs.)CH2112 12R38 4433.49 kg (9774 lbs.)

Chopping Corn HeadModel Header ID Weight kg (lb.)CH2208 8R36 3383.86 kg (7460 lbs.)CH2208 8R38 3429.22 kg (7560 lbs.)

75-2

Specifications

Serial NumberLocate serial number plate on base of the left hand warning light bracket.

Record your corn head serial number in the space above.Give this serial number to your dealer when ordering parts.

Keep Proof of Ownership1. Maintain in a secure location an up-to-date inven-

tory of all product and component serial numbers.

2. Regularly verify that identification plates have not been removed. Report any evidence of tampering to law enforcement agencies and order duplicate plates.

3. Other steps you can take: - Mark your machine with your own numbering

system. - Take color photographs from several angles of

each machine.

Keep Machines Secure1. Install vandal proof devices.

2. When machine is in storage: - Lower equipment to the ground. - Set wheels to widest position to make loading

more difficult. - Remove any keys and batteries.

3. When parking indoors, put large equipment in front of exits and lock your storage buildings.

4. When parking outdoors, store in a well lighted and fenced area.

5. Make note of suspicious activity and report any thefts immediately to law enforcement agencies.

6. Notify your Frontier dealer of any losses.

75-3

Specifications

75-4

Specifications

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